An Algorithm for Generating 3D Lattice Structures Suitable for Printing on a Multi-Plane FDM Printing Platform

2018 ◽  
Author(s):  
Ismayuzri B. Ishak ◽  
Mark B. Moffett ◽  
Pierre Larochelle
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Lattice Structure ◽  
Geometric Model ◽  
Three Dimensional ◽  
Manufacturing Processes ◽  
Lattice Structures ◽  
Fused Deposition ◽  
Structure Generator ◽  
Conventional Machining

Manufacturing processes for the fabrication of complex geometries involve multi-step processes when using conventional machining techniques with material removal processes. Additive manufacturing processes give leverage for fabricating complex geometric structures compared to conventional machining. The capability to fabricate 3D lattice structures is a key additive manufacturing characteristic. Most conventional additive manufacturing processes involve layer based curing or deposition to produce a three-dimensional model. In this paper, a three-dimensional lattice structure generator for multi-plane fused deposition modeling printing was explored. A toolpath for an input geometric model with an overhang structure was able to be generated. The input geometric model was able to be printed using a six degree of freedom robot arm platform. Experimental results show the achievable capabilities of the 3D lattice structure generator for use with the multi-plane platform.

scholarly journals Design of Shoe Soles Using Lattice Structures Fabricated by Additive Manufacturing

2019 ◽  
Vol 1 (1) ◽  
pp. 719-728 ◽  
Author(s):  
Guoying Dong ◽  
Daniel Tessier ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Lattice Structure ◽  
Lattice Structures ◽  
Compression Tests ◽  
Element Analysis ◽  
Fused Deposition ◽  
Footwear Industry ◽  
Deposition Modeling ◽  
Shoe Soles

AbstractAdditive manufacturing (AM) has enabled great application potential in several major industries. The footwear industry can customize shoe soles fabricated by AM. In this paper, lattice structures are discussed. They are used to design functional shoe soles that can have controllable stiffness. Different topologies such as Diamond, Grid, X shape, and Vintiles are used to generate conformal lattice structures that can fit the curved surface of the shoe sole. Finite element analysis is conducted to investigate stress distribution in different designs. The fused deposition modeling process is used to fabricate the designed shoe soles. Finally, compression tests compare the stiffness of shoe soles with different lattice topologies. It is found that the plantar stress is highly influenced by the lattice topology. From preliminary calculations, it has been found that the shoe sole designed with the Diamond topology can reduce the maximum stress on the foot. The Vintiles lattice structure and the X shape lattice structure are stiffer than the Diamond lattice. The Grid lattice structure buckles in the experiment and is not suitable for the design.

scholarly journals High-resolution two-photon polymerization: the most versatile technique for the fabrication of microneedle arrays

2021 ◽  
Vol 7 (1) ◽  
Author(s):  
Zahra Faraji Rad ◽  
Philip D. Prewett ◽  
Graham J. Davies
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Manufacturing Processes ◽  
Two Photon ◽  
Fused Deposition ◽  
Cad Models ◽  
Microneedle Arrays ◽  
Two Photon Polymerization

AbstractMicroneedle patches have received much interest in the last two decades as drug/vaccine delivery or fluid sampling systems for diagnostic and monitoring purposes. Microneedles are manufactured using a variety of additive and subtractive micromanufacturing techniques. In the last decade, much attention has been paid to using additive manufacturing techniques in both research and industry, such as 3D printing, fused deposition modeling, inkjet printing, and two-photon polymerization (2PP), with 2PP being the most flexible method for the fabrication of microneedle arrays. 2PP is one of the most versatile and precise additive manufacturing processes, which enables the fabrication of arbitrary three-dimensional (3D) prototypes directly from computer-aided-design (CAD) models with a resolution down to 100 nm. Due to its unprecedented flexibility and high spatial resolution, the use of this technology has been widespread for the fabrication of bio-microdevices and bio-nanodevices such as microneedles and microfluidic devices. This is a pioneering transformative technology that facilitates the fabrication of complex miniaturized structures that cannot be fabricated with established multistep manufacturing methods such as injection molding, photolithography, and etching. Thus, microstructures are designed according to structural and fluid dynamics considerations rather than the manufacturing constraints imposed by methods such as machining or etching processes. This article presents the fundamentals of 2PP and the recent development of microneedle array fabrication through 2PP as a precise and unique method for the manufacture of microstructures, which may overcome the shortcomings of conventional manufacturing processes.

vELECTROPLATING POLYMER BASED ADDITIVE MANUFACTURED PARTS FOR ENHANCED STRUCTURAL PERFORMANCE

2021 ◽  
Author(s):  
WARUNA SENEVIRATNE, ◽  
JOHN TOMBLIN ◽  
BRANDON SAATHOFF
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Thickness Variation ◽  
Manufacturing Processes ◽  
Fused Deposition ◽  
Aerospace Applications ◽  
Electroplated Coating ◽  
Traditional Manufacturing ◽  
Plastic Parts ◽  
Subtractive Machining

Additive manufacturing has been adopted in many aerospace and defense applications to reduce weight and buy-to-fly ratios of low-volume high- complexity parts. Polymer-based additive manufacturing processes such as Fused Deposition Modeling (FDM) has enabled aerospace manufactures to improve the structural efficiency of parts through generative design or topology optimization. This level of design freedom did not exist in the past due to limitations associated with traditional manufacturing processes such as subtractive machining. Improvements in the material and the maturation of the FDM process has led to the production of many non-structural flightworthy parts used in aircraft today. Polymer-based additive manufacturing can be further leveraged in aerospace applications with the addition of electroplated coatings that act as reinforcement. While many of the commonly known electroplated coating applications involve enhancing the part appearance, electroplated coatings can also improve the strength, stiffness, and durability of plastic parts. Depending on the use case, the thickness of the metallic plating material (combination of copper and nickel) can be tailored to achieve the desired composite properties (metal and polymer). In this research, the tensile and flexural mechanical properties were assessed for Ultem™ 9085 FDM printed specimens and compared to specimens with metallic coating thicknesses of approximately 75-μm, 150-μm, and 300-μm. Non- destructive inspections using x-ray computed tomography were performed prior to mechanical testing to assess the electroplated coating thickness variation and overall quality.

scholarly journals A Review Study on Mechanical Properties of Obtained Products by FDM Method and Metal/Polymer Composite Filament Production

2020 ◽  
Vol 2020 ◽  
pp. 1-9
Author(s):  
Ümit Çevik ◽  
Menderes Kam
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Polymer Composite ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Production Method ◽  
Context Analysis ◽  
Fused Deposition ◽  
Composite Filament ◽  
Metal Polymer

In addition to traditional manufacturing methods, Additive Manufacturing (AM) has become a widespread production technique used in the industry. The Fused Deposition Modeling (FDM) method is one of the most known and widely used additive manufacturing techniques. Due to the fact that polymer-based materials used as depositing materials by the FDM method in printing of parts have insufficient mechanical properties, the technique generally has limited application areas such as model making and prototyping. With the development of polymer-based materials with improved mechanical properties, this technique can be preferred in wider application areas. In this context, analysis of the mechanical properties of the products has an important role in the production method with FDM. This study investigated the mechanical properties of the products obtained by metal/polymer composite filament production and FDM method in detail. It was reviewed current literature on the production of metal/polymer composite filaments with better mechanical properties than filaments compatible with three-dimensional (3D) printers. As a result, it was found that by adding reinforcements of composites in various proportions, products with high mechanical properties can be obtained. Thus, it was predicted that the composite products obtained in this way can be used in wider application areas.

Mechanical characterization of 3D printed, non-planar lattice structures under quasi-static cyclic loading

2020 ◽  
Vol 26 (4) ◽  
pp. 707-717 ◽  
Author(s):  
John C.S. McCaw ◽  
Enrique Cuan-Urquizo
Keyword(s):  
Additive Manufacturing ◽  
Cyclic Loading ◽  
Fused Deposition Modeling ◽  
Mechanical Characterization ◽  
Complex Geometries ◽  
Lattice Structures ◽  
Planar Lattice ◽  
Content Type ◽  
Fused Deposition

Purpose While additive manufacturing via melt-extrusion of plastics has been around for more than several decades, its application to complex geometries has been hampered by the discretization of parts into planar layers. This requires wasted support material and introduces anisotropic weaknesses due to poor layer-to-layer adhesion. Curved-layer manufacturing has been gaining attention recently, with increasing potential to fabricate complex, low-weight structures, such as mechanical metamaterials. This paper aims to study the fabrication and mechanical characterization of non-planar lattice structures under cyclic loading. Design/methodology/approach A mathematical approach to parametrize lattices onto Bèzier surfaces is validated and applied here to fabricate non-planar lattice samples via curved-layer fused deposition modeling. The lattice chirality, amplitude and unit cell size were varied, and the properties of the samples under cyclic-loading were studied experimentally. Findings Overall, lattices with higher auxeticity showed less energy dissipation, attributed to their bending-deformation mechanism. Additionally, bistability was eliminated with increasing auxeticity, reinforcing the conclusion of bending-dominated behavior. The analysis presented here demonstrates that mechanical metamaterial lattices such as auxetics can be explored experimentally for complex geometries where traditional methods of comparing simple geometry to end-use designs are not applicable. Research limitations/implications The mechanics of non-planar lattice structures fabricated using curved-layer additive manufacturing have not been studied thoroughly. Furthermore, traditional approaches do not apply due to parameterization deformations, requiring novel approaches to their study. Here the properties of such structures under cyclic-loading are studied experimentally for the first time. Applications for this type of structures can be found in areas like biomedical scaffolds and stents, sandwich-panel packaging, aerospace structures and architecture of lattice domes. Originality/value This work presents an experimental approach to study the mechanical properties of non-planar lattice structures via quasi-static cyclic loading, comparing variations across several lattice patterns including auxetic sinusoids, disrupted sinusoids and their equivalent-density quadratic patterns.

scholarly journals Toward the integration of lattice structure-based topology optimization and additive manufacturing for the design of turbomachinery components

2019 ◽  
Vol 11 (8) ◽  
pp. 168781401985978
Author(s):  
Enrico Boccini ◽  
Rocco Furferi ◽  
Lapo Governi ◽  
Enrico Meli ◽  
Alessandro Ridolfi ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Three Dimensional ◽  
Optimization Method ◽  
Lattice Structures ◽  
Stiffness Properties ◽  
Maximum Stiffness ◽  
Layer Manufacturing ◽  
Innovative Materials

Used in several industrial fields to create innovative designs, topology optimization is a method to design a structure characterized by maximum stiffness properties and reduced weights. By integrating topology optimization with additive layer manufacturing and, at the same time, by using innovative materials such as lattice structures, it is possible to realize complex three-dimensional geometries unthinkable using traditional subtractive techniques. Surprisingly, the extraordinary potential of topology optimization method (especially when coupled with additive manufacturing and lattice structures) has not yet been extensively developed to study rotating machines. Based on the above considerations, the applicability of topology optimization, additive manufacturing, and lattice structures to the fields of turbomachinery and rotordynamics is here explored. Such techniques are applied to a turbine disk to optimize its performance in terms of resonance and mass reduction. The obtained results are quite encouraging since this approach allows improving existing turbomachinery components’ performance when compared with traditional one.

scholarly journals 3D PRINTER DESIGN, MANUFACTURING AND EFFECT OF INFILL PATTERNS ON MECHANICAL PROPERTlES

2020 ◽  
Vol 4 (1) ◽  
pp. 13-24
Author(s):  
Hande Güler Özgül ◽  
Onur Tatlı
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Tensile Force ◽  
Three Dimensional ◽  
Charpy Impact ◽  
3D Printer ◽  
Direct Production ◽  
Fused Deposition ◽  
Technological Developments ◽  
Manufacturing Technologies

Along with the technological developments, it is an expected situation to discover new developed production methods. Additive manufacturing technologies, such as three-dimensional (3D) printers are one of these methods, allowing direct production of parts with complex geometries that cannot be produced by conventional methods. The most popular and inexpensive method among additive manufacturing technologies is FDM (Fused Deposition Modeling) method. This method is particularly interesting for the manufacture of parts with low production volumes. In this study, a 3D-FDM printer with a print volume of 200x200x210 mm has been designed and manufactured.PLA (polylactic acid) test samples having 2 different infill geometries were produced with the 3D printer. Tensile, three-point bending and charpyimpact tests were applied to these samples to investigate the effect of inner filling geometry on mechanical properties. The inner filling geometries are in the form of grid and gyroid. According to the results, while the geometry with the tensile force is "grid", while the geometry with the maximum bending force is "gyroid".It was concluded that different inner filling geometries do not have a significant impact on Charpy impact strength.

Property Enhancement of Carbon Fiber-Reinforced Polylactic Acid Composites Prepared by Fused-Deposition Modeling

2020 ◽  
pp. 455-478
Author(s):  
Pravin R. Kubade ◽  
Hrushikesh B. Kulkarni ◽  
Vinayak C. Gavali
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Fiber Reinforced ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Properties Of Composites

Additive Manufacturing or three-dimensional printing refers to a process of building lighter, stronger three-dimensional parts, manufactured layer by layer. Additive manufacturing uses a computer and CAD software which passes the program to the printer to build the desired shape. Metals, thermoplastic polymers, and ceramics are the preferred materials used for additive manufacturing. Fused deposition modeling is one additive manufacturing technique involving the use of thermoplastic polymer for creating desired shape. Carbon fibers can be added into polymer to strengthen the composite without adding additional weight. Present work deals with the manufacturing of Carbon fiber-reinforced Polylactic Acid composites prepared using fused deposition modeling. Mechanical and thermo-mechanical properties of composites are studied as per ASTM standards and using sophisticated instruments. It is observed that there is enhancement in thermo-mechanical properties of composites due to addition reinforcement which is discussed in detail.

scholarly journals Systematic Experimental Evaluation of Function Based Cellular Lattice Structure Manufactured by 3D Printing

2021 ◽  
Vol 11 (21) ◽  
pp. 10489
Author(s):  
Shaheen Perween ◽  
Muhammad Fahad ◽  
Maqsood A. Khan
Keyword(s):  
Experimental Evaluation ◽  
Fused Deposition Modeling ◽  
Lattice Structure ◽  
Cylindrical Specimen ◽  
Compressive Load ◽  
Lattice Structures ◽  
Mass Ratio ◽  
Compressive Properties ◽  
Fused Deposition ◽  
Deposition Modeling

Additive manufacturing (AM) has a greater potential to construct lighter parts, having complex geometries with no additional cost, by embedding cellular lattice structures within an object. The geometry of lattice structure can be engineered to achieve improved strength and extra level of performance with the advantage of consuming less material and energy. This paper provides a systematic experimental evaluation of a series of cellular lattice structures, embedded within a cylindrical specimen and constructed according to terms and requirements of ASTMD1621-16, which is standard for the compressive properties of rigid cellular plastics. The modeling of test specimens is based on function representation (FRep) and constructed by fused deposition modeling (FDM) technology. Two different test series, each having eleven test specimens of different parameters, are printed along with their replicates of 70% and 100% infill density. Test specimens are subjected to uniaxial compressive load to produce 13% deformation to the height of the specimen. Comparison of results reveals that specimens, having cellular lattice structure and printed with 70% infill density, exhibit greater strength and improvement in strength to mass ratio, as compared to the solid printed specimen without structure.

Sign in / Sign up

Export Citation Format

Share Document